window air conditioner svc manual(exploded view) · window air conditioner svc manual(exploded...
TRANSCRIPT
Window Air ConditionerSVC MANUAL(Exploded View)MODEL : LP150CED-Y8
CAUTIONBefore Servicing the unit, read the safety precautions in General SVC manual.Only for authorized service personnel.
Internal Use Only
http://biz.lgservice.com
- 2 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
1. SpecificationModelsCooling Capacity kW
Btu/h.Heating Capacity kW
Btu/h.Electric Heater capacity kW kW
Btu/h.Power Input Cooling/Heating WRunning Current Cooling/Heating AStarting current Cooling/Heating AElectric Heater Current AEER W/W
Btu/h.WCOP W/WPower Supply Ø / V / HzPower Factor %MCA AMOP AAir Flow Rate Indoor,Max m3/min(CFM)
Outdoor,Max m3/min(CFM)Moisture Removal l/hSound Level Indoor,H/M/L dB(A)±3(SOUND PRESSURE,1M) Outdoor,Max dB(A)±3Refrigerant & Charge g(oz)Compressor Type
ModelMotor TypeOil TypeOil Charge ccO.L.P Name
Fan Type(In/Out)Motor Type(In/Out)Motor Output(In/Out) W
Heat Exchanger Evaporator Rows*Column*FPICondensor Rows*Column*FPI
Power Supply Cable (Power Cord) No.*mm2
Dimensions ( W * H * D) mminch
Net Weight kg(lbs)Tool Code(Chassis)Features Temperature Control
Energy Saver ModePrefilter(washable/anti-fungus)Plasma FilterSteps, Fan/Cool/HeatAirflow Direction Control(up&down)Airflow Direction Control(left&right)Remote Controller TypeSetting Temperature CoolingRange HeatingAuto Operation (Micom Control)Panel Touch TypeTimerAir DischargeAir-VentilationDefrost ControlHot StartLookCabinet Type(Chassis Type)Special Function
LP150CED-Y84.13 4.19
14100 14300- -- -
3.1 3.510500 119001410 14307.1 6.5- -
14.9 15.22.93 2.9310.0 10.0
- -1 / 208 / 60 1 / 230 / 60
95.5 95.719.220.0
11(390)20(706)
2.049/-/47
63R22, 735(25.9)
Rotary(Non Tropical)QJ196KAC
PSCSUNISO 4GSI
410MRA 98704 - 12026
Cross Flow Fan Axial Fan4 Poles18.4/60
2R *10C *19FPI 2R *17C *18FPI
3 * 2.11066*406*50542*16*19-7/8
50.4(111)YA
ThermistorOO-
2/2/2Manual
-Wall Thermostat
54°F ~ 86°F(12.2°C ~ 30°C)54°F ~ 86°F(12.2°C ~ 30°C)
-Micom
12h, On/OffRear
O--
L - LookSlide In-Out
Electric Heater
Note:O : Applied, - : No relation* For circuit breaker rating, please confirm to local standards wherever necessary.❈ Some of functions are slightly different depending upon models.❈ The specification may be subject to change without prior notice for purpose of improvement.
- 3 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
1.1 FEATURES AND BENEFITS
The PTAC has many features, some of which are different than those found on conventional PTAC units. The servicer must befamiliar with these features in order to properly service the unit.
• IIR (Infinite Impulse Response) The IIR function senses the temperature several times per second and makes micro-adjustments several times per
• Compressor Restart DelayThis feature extends the overall life of compressor by preventing the short-cycling of the air-conditioner. When the compressorrestarts, LG PTAC is designed to give a minimum of three minutes to have a time of equalizing the refrigerant pressures foroptimizing cycling.
• Fan-Only Setting - High/LowThe fan can run at HIGH or LOW speed without COOLING or HEATING to provide air circulation and ventilation.
• Indoor Fan Speed Selections - High/LowThe fan can run at HIGH or LOW speed for either COOLING or HEATING.
• Two Fan motorsThe unit has two fan motors to provide quiet operation and maximum efficiency.
• LED DiagnosticsAll units have this feature indicating the problem when the unit is not operating properly with easy-to-read diagnostics. Forexample, 1 blink every 2 seconds indicates compressor failure.
INDOOR
REAR GRILLE(Aluminum Rear Grille)
EXPANDED METAL GRILLE(Superior for a performance)
SLEEVE ASSEMBLY(Including Aluminum Rear Grille)
THE SLEEVE AND THE REAR GRILLE(Available as an option)
VERTICAL AIR DEFLECTOR(Horizontal Louver)
AIR FILTER
INLET GRILLE(Air Intake)
- 4 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
• Indoor FiltersThe unit uses two indoor filters which slide in and cut easily. The filters may be cleaned by washing and brushing withoutremoving the front grille.
• Rotary CompressorThe unit uses a rotary compressor for quiet, reliable operation and long life.
• 2 Position Discharge GrilleThe discharge grille can provide air flows upward at an angle of 40 off vertical or 15 degree off vertical. The angle is changedby removing the front grille and 4 screws that fasten the discharge grille to the front grille and rotating the louvers to analternate position.
• Indoor Room Freeze ProtectionWhen the unit senses the room temperature falls to less than 40° F the unit activates the fan motor and either the electricresistance heater or the hydronic heater to prevent pipes or fixtures from freezing. This also overrides front desk control of theunit mounted or wall mounted controls.
• Door Switch/Occupancy SensorThe unit is capable of accommodating a field installed door switch and occupancy sensor to operate the energy managementfeature. For additional information, refer to the unit operation section.
• Compressor Overload ProtectionThis feature prevents the damage of the compressor by sensing the indoor tube temperature in heating. If the indoortemperature is over 130˚ F, the outdoor fan will be switched off and back on when the temperature drops below 120˚ F.
• Outdoor Air Temperature SwitchoverThis will effectively change the unit from heat pump mode to total electric resistance heat.
• Temperature limitsThe unit is programmed to provide both heating and cooling temperature limits by dip switches on control panel from 50˚ F to90˚ F. Temperature limits help to prevent overheating and overcooling and reduce energy costs.
• Condensate Drain ValveThe unit has a condensate drain valve to prevent water from collecting or freezing in the basepan.
• Quick Heater RecoveryThe unit is designed to operate the electric heater to warm the room to the temperature set point as soon as heat pump cycleis on in heating. This feature has an advantage of reducing the time to reach the set point and improving the temperatureincrease for better comfort.
• Reverse Cycle Defrosting - (PTHDs only)The unit will activate the reverse cycle defrost when the outdoor coil temperature has remained at a cold temperature to formthe ice on the coil.This ice will reduce airflow though the coil and will also reduce the efficiency of unit. The LG PTHP willemploy an active reverse cycle defrost function to melt the ice off the outdoor coil for insuring room comfort conditions andsavings from extended operation.
• High Temperature Heat Pump Operation ProtectionThe compressor will be switched off to prevent damage when the heat pump is operated in high outdoor temperatures.
• Remote Thermostat ControlEach unit is built to be operated from any standard 4 or 5 wire remote-mounted thermostat, if desired. The unit has a built-inlow voltage power source which can accommodate a large variety of thermostat choices-manual, auto changeover, orprogrammable. A remote thermostat can also be added to any installed unit.
• Zone SensorOccupants enjoy ultimate comfort with consistent climate control. Attach an optional, inexpensive remote Zone Sensor toexactly match the functions of the PTAC without disabling any features.
- 5 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
1.2 CONTROL LOCATIONS• OPERATION
ELECTRIC HEATING MODEL COOLING ONLY MODEL
VENT OPEN
VENT CLOSE
TEMPERATURE CONTROLSet the Thermostat control to the desired temperaturemark 5 (the mid-point is a good starting position). If theroom temperature is not satisfactory after a reasonabletime, adjust the control to a cooler or warmer setting, asappropriate.
OPERATION MODE SELECTOROFF Turns air conditioner off.
LOW FAN Low speed fan operation without cooling.
HIGH FAN High speed fan operation without cooling.
LOW COOL Cooling with the low speed fan operation.
HIGH COOL Cooling with the high speed fan operation.
LOW HEAT Heating with the low speed fan operation.
HIGH HEAT Heating with the high speed fan operation.
• VENTILATIONThe ventilation lever is located to the lower left side of the unit.The ventilation lever must be in the CLOSE position in orderto maintain the best cooling conditions.When fresh air is necessary in the room, set the ventilationlever to the OPEN position. The damper is opened and outdoor air is drawn into the room.This will reduce the cooling or heating efficiency.
When the air conditioner has performed a cooling orheating operation and is turned off or set to the fanposition, wait at least 3 minutes before resetting to thecooling operation.
A slight heat odor may come from the unit when firstswitching to HEAT after the cooling season is over.This odor, caused by fine dust particles on the heater, willdisappear quickly. This is harmless.
CAUTION
NOTE
- 6 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
• ELECTRONIC CONTROLSThe controls will look like one of the following.
TEMP
MODE
HEAT
E/SAVE
FANFAN
COOLCOOL
HIGHHIGH
LOWLOW TIMERTIMER
FAN TIMER
'F
ONOFFONOFF
POWER
MODE- Push this button to cycle through the modes from COOL � FAN � HEAT� COOL.
- COOL• Fan runs continually for normal cooling operation.
- ENERGY SAVER
• The fan stops when the compressor stops cooling. Approximately every 3 minutes the fan will turn on and the unit will check the room air temperature to determine if cooling is needed.
- FAN• Fan operation without heating or cooling.
- HEAT• Fan runs continually for normal heating operation.
TIMER- SHUT-OFF TIME
• You will usually use shut-off time while you sleep.• If unit is running, use Timer to set number of hours until shut-off.• For your sleeping comfort, once Time is set, the Temperature setting will raise 2° F after 30 minutes, and once again
after another 30 minutes.• Push Timer to cycle through the settings from 1 Hour � 2 Hours � ... � 12 Hours maximum.
TEMPERATURE SETTING• Use this button to automatically control the
temperature of the room. The temperature can be set within a range of 54° F to 86° F by increments of 2° F.
• The setting appears in the display.
FAN SPEED• Every time you push this button, it cycles through the settings as follows:
{High(F2) � Low(F1) � High(F2) � Low(F1)}
• To turn the air conditioner ON, push this button. To turn the air conditioner OFF, push the button again.
• This button takes priority over any other button.
- 7 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
• REMOVING THE FRONT GRILLEAdditional controls are available after removing the frontgrille and option cover of control box.To remove the front grille, pull out the bottom of frontgrille and then lift up.To replace the front grille, place the tabs over the top ofthe unit and push the bottom of front grille until the clipssnap into place.
• ADDITIONAL CONTROLSThe additional controls are located behind the option cover of control box. The standard settings will be in the OFF position.The authorized servicer has to check switches and ensure the switches are in the desired position.
• TEMPERATURE LIMITINGTemperature Limiting can save money by limiting the lowest temperature for cooling and the highest temperature for heating.The temperature limiting is controlled by switches #1 - #3.This temperature limiting is not available with the Remote Wall Thermostat.
LOCAL1
OFF2
OFF3
OFF4
OFF5
LOCAL1
OFF2
OFF3
OFF4
OFF5
LOCAL1
OFF2
OFF3
OFF4
OFF5
ONONREMOTE
OFF
ON ON ON
Remote/LocalEnergy SaverTemperature Limit 1Temperature Limit 2Temperature Limit 3PTAC/PTHPUNIT TYPE
LOCALLOCAL1
OFFOFF2
OFFOFF3
OFFOFF4
OFFOFF5
LOCAL1
OFF2
OFF3
OFF4
OFF5
LOCALLOCAL1
OFFOFF2
OFFOFF3
OFFOFF4
OFFOFF5
LOCAL1
OFF2
OFF3
OFF4
OFF5
OFF6
OFF7
LOCALLOCAL1
OFFOFF2
OFFOFF3
OFFOFF4
OFFOFF5
LOCAL1
OFF2
OFF3
OFF4
OFF5
OFF OFF OFF 54° F (12.2° C) 86° F (30.0° C)
86° F (30.0° C)
86° F (30.0° C)
86° F (30.0° C)
86° F (30.0° C)
86° F (30.0° C)
86° F (30.0° C)
86° F (30.0° C)
54° F (12.2° C)
54° F (12.2° C)
54° F (12.2° C)
54° F (12.2° C)
54° F (12.2° C)
54° F (12.2° C)
54° F (12.2° C)
54° F (12.2° C)
86° F (30.0° C)
ON OFF OFF 56° F (13.3° C) 84° F (28.9° C)
OFF ON OFF 58° F (14.4° C) 82° F (27.8° C)
ON ON OFF 60° F (15.5° C) 80° F (26.7° C)
OFF OFF ON 62° F (16.6° C) 78° F (25.5° C)
ON OFF ON 64° F (17.7° C) 76° F (24.4° C)
OFF ON ON 66° F (18.9° C) 74° F (23.3° C)
ON ON ON 68° F (20.0° C) 72° F (22.2° C)
Temperature Temperature Temperature Limit #1 Limit #2 Limit #3 Lowest Temp. Highest Temp. Lowest Temp. Highest Temp.
Cooling Operation Heating Operation
Cooling+Electric Heater+Heat PumpOFFOFF
Cooling+Electric HeaterONOFF
Cooling OnlyHeat Pump Only
Unit Type
ONOFF
#7
ONON
#6
1.3 ADDITIONAL CONTROLS
- 8 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
• TEMPERATURE LIMITINGTemperature Limiting can save money by limiting the lowest temperature for cooling and the highest temperature for heating.The temperature limiting is controlled by dip switch #1 - #3. This temperature limiting is not available with the Remote Wall Thermostat.
OFF OFF OFF 54°F (12.2°C) 86°F (30.0°C) 54°F (12.2°C) 86°F (30.0°C)
ON OFF OFF 56°F (13.3°C) 86°F (30.0°C) 54°F (12.2°C) 84°F (28.9°C)
OFF ON OFF 58°F (14.4°C) 86°F (30.0°C) 54°F (12.2°C) 82°F (27.8°C)
ON ON OFF 60°F (15.5°C) 86°F (30.0°C) 54°F (12.2°C) 80°F (26.7°C)
OFF OFF ON 62°F (16.6°C) 86°F (30.0°C) 54°F (12.2°C) 78°F (25.5°C)
ON OFF ON 64°F (17.7°C) 86°F (30.0°C) 54°F (12.2°C) 76°F (24.4°C)
OFF ON ON 66°F (18.9°C) 86°F (30.0°C) 54°F (12.2°C) 74°F (23.3°C)
ON ON ON 68°F (20.0°C) 86°F (30.0°C) 54°F (12.2°C) 72°F (22.2°C)
Temperature Temperature Temperature Limit #1 Limit #2 Limit #3 Lowest Temp. Highest Temp. Lowest Temp. Highest Temp.
Cooling Operation Heating Operation
• REMOVING THE FRONT GRILLEAdditional controls are available after removing the front grilleand option cover of control box.To remove the front grille, pull out the bottom of front grille andthen lift up.
To replace the front grille, place the tabs over the top of theunit and push the bottom of front grille until the clips snap intoplace.
• ADDITIONAL CONTROLSThe additional controls are located behind the option cover of control box. The standard settings will be in the OFF position.The authorized service man has to check switches and ensure the switches are in the desired position.
LOCAL1
OFF2
OFF3
OFF4
OFF5
LOCAL1
OFF2
OFF3
OFF4
OFF5
ONONREMOTE
OFF
ON ON ON
Remote/LocalEnergy SaverTemperature Limit 1Temperature Limit 2Temperature Limit 3
LOCAL1
OFF2
OFF3
OFF4
OFF5
LOCAL1
OFF2
OFF3
OFF4
OFF5
LOCAL1
OFF2
OFF3
OFF4
OFF5
LOCAL1
OFF2
OFF3
OFF4
OFF5
- 9 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
Wiring Schematic forRemote Heat Pump
Wiring Schematic forStraight Cool Unit.
• REMOTE/LOCAL CONTROLWhen remote/local switch #1 is on, it allow the unit to operate by the Remote Wall Thermostat.The unit control by knobs are not available.
• ENERGY SAVERThe energy saver switch #2 is on. This switch is set at cycle fan to provide continuous fan operation in cool or heat modes.When the switch is off the continuous fan allows continuous circulation of room air and make the more balanced temperatureof the room. When the switch is on, the fan is on or off with the compressor or with the heater.
• FRONT DESK CONTROLWhen the pair wire is connected to the connector FD2 and FD1, the unit can be turned ON or OFF with a switch located at theFront Desk Control panel. When the front desk switch is ON, the fan operates according to the setting without workingcompressor and heater. When the front desk switch is OFF, the unit can operate according to the setting of controls.
• REMOTE WALL THERMOSTATWhen the wires are connected, the unit will be controlled by a remote wallthermostat.The thermostat connections supply the 24 Volt AC. When you install thedigital/electronic thermostat, you must set it to 24 Volt AC. See theinstallation Instruction in this manual for the Remote Wall Thermostat.
Note: The following figures show wiringschematics for heat pump and straightcool units with electric heat, respectively.
GL GH O W Y R C
Low Fan
High Fan
Reversing Valve
Heater
Compressor
24 Volt-L
24 Volt-N
Wire # AWG Maximum Length#22 600 ft (180 m)#20 900 ft (270 m)#18 1500 ft (450 m)#16 2000 ft (610 m)
FD2 FD1 DR2 DR1 MS2 MS1
Front Desk ControlFront Desk ControlDoor SwitchDoor SwitchMotion SensorMotion Sensor
(Molex Housing Spec 396-06V)
(Molex Housing Spec 396-07V)
- 10 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
(Molex Housing Spec 396-09V)
• FRONT DESK CONTROLWhen the pair wire is connected to the connector LOand LI, the unit can be turned ON or OFF with a switch located at theFront Desk Control panel. When the front desk switch is ON, the fan operate according to the condition of setting withoutworking compressor and heater. When the front desk switch is OFF, the unit can operate according to the setting of controls.
• REMOTE WALL THERMOSTATWhen the wires are connected, the unit will be controlled by aremote wall thermostat.
The thermostat connections supply the 24 Volt AC. When youinstall the digital / electronic thermostat, you must set it to the24 Volt AC. See the installation Instruction in this manual forthe Remote Wall Thermostat.
• REMOTE/LOCAL CONTROLWhen remote/local switch #1 is on, it allow the unit to operate by the control of Remote Wall Thermostat. The unit control byknobs are not available.
• ENERGY SAVERThe energy saver switch #2 is on. This switch is set at continuous fan to provide continuous fan operation in cool or heatmodes. When the switch is off the continuous fan allows continuous circulation of room air and make the more balancedtemperature of the room. When the switch is on the fan is on or off with the compressor or with the heater.
Wire # AWG Maximum Length#22 600ft(180m)#20 900ft(270m)#18 1500ft(450m)#16 2000ft(610m)
GL GH O W Y R CLO LI
Front Desk Switch
LO LI GL GH O W Y R C
Low FanHigh FanReversing ValveHeaterCompressor24 Volt-L24 Volt-N
Wiring Schematic forRemote Heat Pump
Wiring Schematic forStraight Cool Unit.
Note:The following figures showwiring schematics for heat pumpand straight cool units with electricheat, respectively.
- 11 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
2.1 MECHANICAL PARTS2.1.1 FRONT GRILLE1. Remove the front grille. (See Figure 1)2. To remove the front grille, pull out the bottom of
the front grille and then lift up.Re-install the component by referring to theremoval procedure.
3. To replace the front grille, place the tabs over thetop of the unit and push the bottom of front grilleuntil the clips snap into place.
• This Room Air Conditioner (PTAC) discharges airfrom the top of the unit through reversible, 2-positiondischarge grille louvers. The unit is shipped from thefactory with the discharge grille louvers at an angleof 40˚ off vertical. In the alternate position, thelouvers will be at an angle of 15˚ off vertical.
To adjust air direction, remove the front grille.Remove the 4 screws that fasten the discharge grilleto the front grille.
Flip the discharge grille 180°, then reattach thedischarge grille to the front grille with 4 screws.
— Before the following disassembly, POWER SWITCH is set to OFF and disconnected the power cord.
Figure 1
40˚
15˚
Screws
2. disassembly instructions
- 12 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
2.1.2 CONTROL BOX
1. Remove the front grille. (Refer to section 2.1.1)2. Remove the two screws which fasten the control
box. (See Figure 2) 3. Pull the control box from the Air guide.
4. Remove the control box cover. (See Figure 3) 5. Disconnect wire housings on the control box.
6. Pull the control box assembly out from the unit.(See Figure 4)
7. Re-install the components by referring to theremoval procedure.
Figure 2
Figure 3
Figure 4
- 13 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
Figure 8
2.2 AIR HANDLING PARTS
2.2.1 ELECTRIC HEATER (ELECTRIC HEATER MODEL ONLY)
1. Remove the front grille.(Refer to section 2.1.1)2. Remove the control box assembly.
(Refer to section 2.1.2) 3. Remove the 4 screws which fasten the Evaporator.
(See Figure 5)
4. Remove the top cover assembly, net steel, brace.(See Figure 6)
5. Remove the 6 screws which fasten the Air-guide.6. Pull the Air-guide assembly out from the unit.
(See Figure 7)
7. Remove the 2 screws which fasten the electricheater in the left hand side.
8. Pull the electric heater towards left for a while andthen lift up vertically to disassemble it completelyfrom Air guide.
Figure 5
Figure 6
Figure 7
- 14 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
Figure 12
2.2.2 CROSS FLOW FAN
1. Remove the front grille. (Refer to section 2.1.1)2. Remove the control box assembly.
(Refer to section 2.1.2) 3. Remove the Air-Guide Assembly from the unit.
(Refer to section 2.2.1)4. Loosen the screw on the cross flow fan.
(See Figure 9)
5. Remove the 4 screws which fasten the indoormotor and the earth wire. (See Figure 10)
6. Remove the supports on both sides.7. Pull the cross flow fan out from the air-guide.8. Re-install the components by referring to the
removal procedure.
2.2.3 AXIAL FAN
1. Remove the brace.2. Remove the 4 screws which fasten the condenser
with the shroud and the basepan. (See Figure 11) 3. Remove the condenser sideways carefully.
4. Remove the clamp which secures the fan withpliers.(See Figure 12)
5. Remove the axial fan.6. Re-install the components by referring to the
removal procedure.
Figure 9
Figure 10
Figure 11
- 15 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
2.2.4 SHROUD1. Remove the axial fan. (Refer to section 2.2.3)2. Remove the 4 screws which fasten the condenser
with the shroud and the basepan. (See Figure 11) 3. Remove the shroud. 4. Re-install the component by referring to the
removal procedure.
2.3. ELECTRICAL PARTS2.3.1 OUTDOOR MOTOR1. Remove the clamp cord and disconnect a wire
housing in control box. (Refer to section 2.1.2)2. Remove the axial fan. (Refer to section 2.2.3) 3. Remove the 2 screws which fasten the motor.
(See Figure 12) 4. Remove the motor5. Re-install the component by referring to the
removal procedure, above.
2.3.2 INDOOR MOTOR (Refer to section 2.2.2)
2.3.3 COMPRESSOR1. Discharge the refrigerant system using a
refrigerant recovery system.If there is no valve to attach the recovery system,install one (such as a WATCO A-1) before ventingthe refrigerant. Leave the valve in place after servicing the system.
2. Disconnect the 3 leads from the compressor.3. After purging the unit completely, unbraze the
suction and discharge tubes at the compressorconnections.
4. Remove the 3 nuts and the 3 washers whichfasten the compressor. (See Figure 15)
5. Remove the compressor. 6. Re-instill the components by referring to the
removal procedure, above.
2.3.4 CAPACITOR1. Remove the control box. (Refer to section 2.1.2)2. Remove 1 screw and disconnect the leads which
connected to the box type capacitor. (See Figure 16)
3. Remove 1 screw and the clamp which fastens thecan-type capacitor.
4. Disconnect all the leads of capacitor terminals.5. Re-install the components by referring to the
removal procedure, above.
Figure 13
Figure 14
Figure 15
Figure 16
- 16 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
2.3.5 POWER CORD1. Remove the control box. (Refer to section 2.1.2)2. Disconnect the grounding screw from the control
box.3. Disconnect 2 receptacles.4. Remove a screw which fastens the clip cord.5. Separate the power cord from the control box.
(See Figure 17)6. Re-install the component by referring to the
removal procedure, above.(Use only one ground-marked hole for groundconnection.)
7. If the supply cord of this appliance is damaged, itmust be replaced by an exact replacement part. (The special cord means the cord which has thesame specification marked on the supply cordfitted to the unit.)
2.3.6 P.C.B.1. Remove the escutcheon.2. Remove the two knobs.3. Remove the 2 screws which fasten P.C.B. cover.4. Disconnect all the leads which connected to the
P.C.B.5. Remove the two screws which fasten the P.C.B.
board.6. Re-install the components by referring to the
removal procedure, above.
Figure 17
Figure 18
After servicing control box ,make sure that AC and DCwires are separated and tied up properly.
The wires should also be pressed a little downwards toprevent touching it to the display pcb.
WARNING
- 17 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
2.4 REFRIGERATION CYCLE
2.4.1 CONDENSER1. Remove the brace and the shroud.
(Refer to section 2.2.2)2. Remove the 4 screws which fasten the shroud.
(Refer to section 2.2.2)3. Push forward the shroud and remove the 2 screws
which fasten the condenser with the basepan.4. After discharging the refrigerant completely,
unbraze the interconnecting tube at the condenserconnections.
5. Remove the condenser.6. Re-install the components by referring to notes.
(See Figure 19)
2.4.2 EVAPORATOR1. Remove the front grille. (Refer to section 2.1.1)2. Discharge the refrigerant completely.3. Remove the control box assembly.
(Refer to section 2.1.2)4. Remove the 4 screws which fasten the evaporator
at the left side and the right side.5. Move the evaporator sideward carefully and then
unbraze the interconnecting tube at the evaporatorconnectors.
6. Remove the evaporator.7. Re-install the components by referring to notes.
(See Figure 20)
2.4.3 CAPILLARY TUBE1. After discharging the refrigerant completely,
unbraze the interconnecting tube at the capillarytube.
2. Remove the capillary tube.3. Re-install the components by referring to notes.
Figure 19
Figure 15
Discharge the refrigerant system using arefrigerant recovery system.If there is no valve to attach the recovery system,install one (such as a WATCO A-1) beforeventing the refrigerant. Leave the valve in placeafter servicing the system.
CAUTION
Figure 20
- 18 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
— Replacement of the refrigeration cycle.
1. When replacing the refrigeration cycle, be sure todischarge the refrigerant system using arefrigerant recovery system.If there is no valve to attach the recovery system,install one (such as a WATCO A-1) before ventingthe refrigerant. Leave the valve in place after servicing the system.
2. After discharging the unit completely, remove thedesired component, and unbraze the pinch-offtubes.
3. Solder service valves into the pinch-off tube ports,leaving the valves open.
4. Solder the pinch-off tubes with service valves.5. Evacuate as follows.
1) Connect the vacuum pump, as illustrated Figure 16 A.
2) Start the vacuum pump, slowly open manifold valves A and B with two full turnscounterclockwise and leave the valves closed.The vacuum pump is now pulling through valvesA and B up to valve C by means of the manifoldand entire system.
3) Operate the vacuum pump for 20 to 30 minutes, until 600 microns of vacuum are obtained. Close valves A and B, and observe the vacuum gaugefor a few minutes. A rise in pressure would indicate a possible leak or moisture remaining inthe system. With valves A and B closed, stop the vacuum pump.
4) Remove the hose from the vacuum pump andplace it on the charging cylinder. See Figure 16 B.Open valve C.Discharge the line at the manifold connection.
5) The system is now ready for final charging.
6. Recharge as follows :1) Refrigeration cycle systems are charged from the
high-side. If the total charge cannot be put in the high-side, the balance will be put in the suction line through the access valve which you installed as the system was opened.
2) Connect the charging cylinder as shown in Figure16B.With valve C open, discharge the hose at themanifold connection.
3) Open valve A and allow the proper charge to enter the system. Valve B is still closed.
4) If more charge is required, the high-side will not take it. Close valve A.
5) With the unit running, open valve B and add the balance of the charge.
a. Do not add the liquid refrigerant to the low-side.
b. Watch the low-side gauge; allow pressure to rise to 30 lbs.
c. Turn off valve B and allow pressure to drop.d. Repeat steps B and C until the balance of the
charge is in the system.6) When satisfied the unit is operating correctly,
use the pinch-off tool with the unit still running and clamp on to the pinch-off tube. Using a tube cutter, cut the pinch-off tube about 2 inches from the pinch-off tool. Use sil-fos solder and solder pinch-off tube closed. Turn off the unit, allow it to set for a while, and then test the leakage of the pinch-off connection.
NOTES
If high vacuum equipment is used, just crackvalves A and B for a few minutes, then openslowly with the two full turns counterclockwise.This will keep oil from foaming and beingdrawn into the vacuum pump.
CAUTION
- 19 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
Equipment needed: Vacuum pump, charging cylinder, manifold gauge, brazing equipment. pinch-off tool capableof making a vapor-proof seal, leak detector, tubing cutter, hand tools to remove components, service valve.
A
COMPOUND GAUGE
EVAPORATOR(LOW PRESSURE SIDE)
COMPRESSOR
CAPILLARY TUBE
CONDENSER(HIGH PRESSURE SIDE)
SEE INSETSBELOW
MANIFOLDGAUGE
B
Figure 16 A-Pulling Vacuum Figure 16 B-Charging
AB
EXTERNALVACUUM PUMP
A
CHARGINGCYLINDER
LOW HI
B
C
- 20 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
3.1 HOW TO INSTALL THE UNIT
For existing sleeve, you should measure the wall sleevedimensions.Install the new air conditioner according to these installationinstructions to achieve the best performence. All wall sleevesused to mount the new air conditioner must be in goodstructural condition and have a rear grille that securelyattaches to the sleeve or the flange of the sleeve to secure thenew air conditioner.
• To avoid vibration and noise, make sure the unit is installedsecurely and firmly.
When installing the sleeve, make certain there is nothingwithin 20" of the back that would interfere with heat radiationand exhaust air flow.
1) Take out the insulation strip from the upper packing.
2) Attach the insulation strip onto the rear upper side of thewall sleeve.
3) To improve unit energy efficiency, it is recommended thechange of outside grille for an unit protection and anaddition of a plastic rear grille. (This is optional.)
4) Insulation strip prevents the exhaust air from re-enteringfrom either side of condenser space which may decreasethe cooling efficiency of condenser.
406 mm(16")
1,066 mm(42")
349 mm(13 3/4")
505 mm(20")
42"
13-3/4"
16"1-1/2" TYP 1/2"
6"21"
36"
1/2" SQ. HOLE (2 REQ'D.)
1/2" DIA.HOLE (3 REQ'D.)
2-3/4"
5-5/8"4"
Over 20"
HEATRADIATION
WALL
WALL
INSULATION SLEEVE
INTAKEAIR
COOLEDAIR
1/4" Bubbleof the level
Front Insulation Strip
Rear
Sleeve
280 mm (11")
• There are sharp edges that can cause serious cuts.• When lifting the air conditioner, it is HEAVY.
Use 2 people to lift.
CAUTION
Dimension of air conditioner
Dimension of sleeve assembly (optional)
Wall opening 16-1/4"x42-1/4"
Insulation strip must be attached to prevent the re-circulation of exhaust airto inward side from the either side of condenser space. The insulationstrip is provided with the box.Refer to the diagram below.
Recommended
13-3/4"
42"
TOP VIEW
GRILLE
ROOMCABINET
3. Installation
- 21 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
3.2 WALL SLEEVE INSTALLATION
3.2.1 Wall Case Installation DataGeneral Generally, units are installed 3" to 5" above the floor(flush to finished floor installation is possible) as near tothe center of the room as possible; underneath awindow or a glass panel is typical. Normal installation ofthe wall case allows installation flexibility; from flushwith the finished interior wall to a minimum of 1/4" of thewall case extending beyond the finished exterior of thebuilding. Special consideration must be given to installationswhere the wall case does not extend a minimum of 1/4"beyond the finished exterior wall.
Regardless of the installation, there are several thingsto consider when selecting a location for installing theunit. For instance, drapery location could interfere withair discharge, and placement of furniture may have animpact on the performance of the unit. The followinginformation is intended to minimize installationproblems and assure you of trouble-free installation.
Refer to page 20 for required wall opening dimensions.Minimum recommended interior and exterior caseprojection for standard wall thicknesses are shown inthe drawings in this manual. The case may be installedflush with the finished indoor wall.
Mounting an outdoor grille or louver section to thebuilding face may cause a space between the outdoorcoil and the louver section. Air splitters, aligned with theends of the outdoor coil, must be installed between theoutdoor coil inlet and outlet air streams. Gaps betweenthe outdoor coil and the louver section may allowcondenser air recirculation and affect the operation ofthe unit. See page 40 for requirements for customlouver sections.
For new construction, early planning with the architectis necessary. Unit location, electrical connectionlocations, and wall openings of the proper dimensionsare essential to avoid the necessity of rework, fillers,
framing, moving electrical outlets, and other expensivemodifications.
For existing construction it is important that carpentry,masonry and electrical work be performed bycompetent, qualified personnel. Since installations inexisting construction may involve removal ofbuilding material from the structure, locating thewall case must be done correctly.
The wall case should be level from side to sideand from level to 1/4 bubble tilt to the outdoors.The condensate disposal system in the unit isdesigned to dissipate the condensate watergenerated during cooling operation inaccordance with ARI standards and actuallyuses this water for maximum unit efficiency. Alevel unit will also insure proper performance ofthe Internal Condensate Removal (ICR) systemoptional on heat pump units.
- 22 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
3.2.2 PREPARATION OF THE FRONTGRILLE
Carefully remove shipping tape from the front grille.
Brick, Frame, Stucco and Shingle ConstructionFor new construction, the opening for the wall case should beframed and the wall case inserted into the opening duringconstruction. Lintels should be used when the buildingmaterial is heavy and is not self supporting (such as brick).The wall case will fit an opening of six courses of standardbrick or five courses of jumbo brick. Wall framing in this typeconstruction is normally on 16" centers and the wall case willfit a framed opening spanning three 16" O.C. 2" x 4" studspaces.
For existing construction the indoor and outdoor wall will needto be cut out, allowing for clearances of 1/8" on all sides of thewall case. Work should begin on the inside wall.Cut the correct dimensions and mark (using drill holes) theoutside wall from each corner of the inside cutout. Studdingthat interferes with the opening must be removed and asuitable frame constructed to secure the wall case andprovide adequate support for case and chassis.
Preparation of the Wall Case for All Types ofConstructionAs shipped, the LG wall sleeve is ready for installation.Do not remove the stiffener from inside the wall case or theweather closure panel from the outside face of the wall caseuntil the outdoor grille and chassis are ready to be installed.
Installation of Wall Case in Wall Opening1. Position the wall case into the wall. The room side edge of
the wall case should be at least flush with the finished wallfor line cord installations and permanent connectioninstallations when no sub-base is used, and should projectinto the room at least 2-3/8" when a sub-base is used. If theminimum exterior dimensions are not met, refer to page 23.
The outside edge of the wall case should extend at least1/4" beyond the outside wall.This is necessary for proper caulking, to prevent sealingthedrain holes in the rear flange of the wall case, and tofacilitate the installation of an accessory drain, if used.
2. The wall case should be secured to the wall at both sides.Use a minimum of two screws or other fastening device oneach side. See Figure 2 page 24. Mark the wall case oneach side 2" from the bottom and 2" from the top at a pointwhere basic wall structure is located. Drill wall case anduse fasteners appropriate for wall construction. All holes forfasteners in the side of the wall case must be at least 2" upfrom the bottom of the wall case. Never locate screws orput other holes in the bottom of the wall case. If the wall opening is greater than the case dimensions,spacers must be used on the sides between the wall caseand the wall support structure to prevent distorting the wallcase.
3. Caulk or gasket the entire opening on the outside betweenthe wall case and exterior wall surface (4 sides) to providetotal water and air seal.
4. Caulk or gasket room-side opening between wall case andinterior wall surface (4 sides). Opening beneath or aroundthe wall case can allow outdoor air to leak into the roomresulting in increased operating costs and improper roomtemperature control.
Care should be taken in location of electrical supply entryin relationship to wall sleeve to assure access toreceptacle or junction box once unit is installed.
11
1
Shipping Tape
The wall case should be level from side to sideand from level to 1/4 bubble tilt to the outdoors.The condensate disposal system in the unit isdesigned to dissipate the condensate watergenerated during cooling operation inaccordance with ARI standards and actuallyuses this water for maximum unit efficiency. Alevel unit will also insure proper performance ofthe Internal Condensate Removal (ICR) systemoptional on heat pump units.
- 23 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
- 24 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
WA
LL
SE
CT
ION
– D
ETA
ILE
D S
IDE
VIE
W
FR
AM
E A
ND
BR
ICK
VE
NE
ER
IN
STA
LLA
TIO
N
Co
rd S
et
Co
nn
ecte
d
CA
ULK
*
Su
b-B
ase
Co
nn
ecte
d
CA
ULK
*
ST
EE
L LI
NT
EL
RA
B71
1
3-3/
4"R
AB
77
13-
7/8"
20-7
/8"
(R
AB
71)
21"
(RA
B77
)
RO
OM
CA
BIN
ET
2" M
IN.
MO
UN
TIN
G S
CR
EW
SB
Y IN
STA
LLE
R
WA
LL C
AS
E
OU
TD
OO
RG
RIL
LE
CA
ULK
*
CA
ULK
*
1/4"
MIN
.
PO
WE
R S
UP
PLY
CO
ND
UIT
WA
LL R
EC
EP
TAC
LE(B
Y O
TH
ER
S)
FIN
ISH
ED
FLO
OR
OR
TO
P O
FC
AR
PE
T
*Cau
lk a
rou
nd
per
imet
er o
f w
all c
ase
all f
ou
r si
des
wh
ere
it jo
ins
the
bu
ildin
g -
Inte
rio
r an
d E
xter
ior.
CA
ULK
*
1/4"
CA
ULK
*
LIN
TE
L
RO
OM
CA
BIN
ET
2" M
IN.
MO
UN
TIN
G S
CR
EW
SB
Y IN
STA
LLE
R
WA
LL
CA
SE
OU
TD
OO
RG
RIL
LE
SID
E C
HA
NN
EL
3" M
IN.
5" M
AX
.
1-5/
16"
FIN
ISH
ED
FLO
OR
OR
TO
P O
FC
AR
PE
T
SU
B-B
AS
E(R
AK
204)
CA
ULK
*
PO
WE
R S
UP
PLY
CO
ND
UIT
(ALT
ER
NA
TE
EN
TR
Y)
3-11
/16"
*Cau
lk a
rou
nd
per
imet
er o
f w
all
case
all
fou
rsi
des
wh
ere
itjo
ins
the
bu
ildin
g-
Inte
rio
r an
dE
xter
ior.
2-3/
8"
- 25 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
3.2.3 UNIT INSTALLATION
1. Remove the shipping screw from the ventilation door.(See Figure 17)
2. Remove the front gille by pulling it out at the bottom torelease it, then lift it up along the unit top front.(See Figure 18)
3. Slide the unit into the wall sleeve and secure with 6 screwsthrough the unit flange holes. (See Figure 19)
4. Reinstall the front grille by hooking the top over the unit top,then pushing it in at the bottom. (See Figure 20)
Figure 17
Figure 18
Figure 19
Figure 20
- 26 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
Perpendicular20 A
Tandem15 A
Large Tandem30 A
230/208 volt receptacle configuration
CAUTION
1. Do not use an extension cord with this unit.2. When the unit is in the OFF position, the power supply to the
electrical controls is still energized.3. Disconnect the power to the unit before servicing
the unit.4. Remove the power cord from the wall receptacle.5. Remove or turn off the protective device (fuses or circuit breaker).
Wirings including installation of the receptacle must comply with theNEC and local codes, local regulations.
FUSE- Use a time-delay fuse or circuit breaker. Refer to the nameplatefor proper power supply requirements.
3.3.1 ELECTRICAL DATA (FOR 230/208V MODEL)
3.3.2 ELECTRICAL SAFETY
IMPORTANT GROUNDING INSTRUCTIONSThe air conditioner has a three-prong grounding plug on its power supply cord which must be plugged into properly groundedthree-prong wall receptacle for your protection against possible shock hazard. FUSE – Use a time-delay fuse or circuit breaker. Refer to the nameplate for proper power supply requirements. 208, 230, and 208/230 VOLT UNITSThese units are equipped with a three-prong grounding plug on the power supply cord which must be plugged into a matchingproperly grounded three-prong wall receptacle for your protection against possible shock hazard. If such an outlet is notpresent, one must be installed by a qualified electrician in accordance with the National Electrical Code and local codes andordinances. NOTE: DO NOT USE AN EXTENSION CORD on 208, 230, and 208/230 Volt units.
3.3 ELECTRICAL REQUIREMENTS
- 27 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
Control Panel Key LockPart No: AYCP101
DescriptionThe Key Lock kit prevents tampering of the controls used toset temperatures and heating or cooling functions.
ReceivingUpon receipt of the product, inspect the shipping carton forsigns of visible damage. Report any damage or shortage tothe carrier and note it on the delivery receipt. Unit must bestored in its original shipping carton in a dry, secure placeprior to its installation and use.
InstallationThe installation and servicing of the equipment referred to inthis booklet should be performed by qualified, experiencedtechnicians.
1. Remove front from unit by pulling bottom out and thenlifting upward. (Figure 21)
2. Remove existing door assembly by lifting door halfway andusing both hands, bow door just enough for door hinge pinsto slide out of mating holes. (Figure 22)
3. Install the new door assembly with the key lock by bowingthe door with both hands and aligning the door hinge pinswith their bracket in the front. (Figure 23)
Important Note:Personal Risk Hazard Underwriter’s Laboratories Inc. listed.For institutional use only where supervisory monitoring isavailable. Any other use may increase the risk of personal injury orproperty damage.
Note: The installation and servicing of this equipment must be performed by qualifieed.experienced technicians
NOTICE:Warnings and Cautions appear at appropriate sections throughout this manual. Read these carefully.
WARNING - Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION - Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It mayalso be used to alert against unsafe practices.
CAUTION –Indicates a situation that may result in equipment or property-damage-only accidents.
Door
Front
Hinge Pins(Each Side)
Brackets(Each Side)
Figure 21 - Remove Front
Figure 22 - Door Removal
Figure 23 - New Door Installation
4. Field installed accessories
- 28 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
Condensate Disposal Pump KitInstallationPart No: AYSB2101
DescriptionThe internal condensate pump serves as a means fordisposing of condensate generated during heat pumpoperation by transferring it to the indoor coil. The warm coilsurface and the warm room air help in evaporation of thecondensate while adding humidity to the room.As with any equipment of this type, the addition of this kit willdecrease the effective heating capacity of the unit. This kit isnot intended for use in seacoast or corrosive environments.
NOTE:Under extreme high humidity conditions, the internalcondensate pump may not be able to dispose of all thecondensate produced, and condensate would then drip fromthe outside of the wall sleeve. If this condensation isunacceptable, then a drain system (including factoryapproved drain kit for the wall sleeve) should be installed.
ReceivingUpon receipt of the product, inspect the shipping carton forsigns of visible damage. Report any damage or shortage tothe carrier and note it on the delivery receipt. Unit must bestored in its original shipping carton in a dry, secure placeprior to its installation and use.
InstallationThe installation and servicing of the equipment referred to inthis booklet should be performed by qualified, experiencedtechnicians.
WARNING
Hazardous Voltage!Disconnect all electric power, including remote disconnectsbefore servicing. Follow proper lockout/tagout procedures toensure the power can not be inadvertently energized. Failureto disconnect power before servicing could result in death orserious injury.
Important Note:The unit OFF switch does not disconnect all electrical powerto this unit.
1. Remove front plastic cover by rotating bottom outward andthen lifting up and out from chassis.
2. Unplug and remove the PTAC chassis from the wallsleeve.Movethe chassis where the front and back of the chassiscan be easily accessed.
3. Remove the wire junction box cover by removing fourscrews and lifting up as shown in fig. 24
4. Remove and set aside the air discharge screen byunscrewing the 5 screws on the top.
5. Remove the one screws holding the control board cover as shown fig. 25.Remove the cover by lifting it up so its free from its hinges,and put aside.
6. Unplug the electric heater connecter located inside the wirejunction box.
Figure 24
Figure 25
- 29 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
7. Remove the screw that attaches the electric heater wire tothe side of the indoor fan housing.
8. Remove the 3 screws which fasten the top cover assembly.
9. Position water spraying plastic tube into the electric heatercover. Make sure that the three pairs(total of six) of plastictongues snap into the corresponding metal slots of theheater frame as shown in fig. 27. Then install one of thethree rubber elbows(ref. fig. 31) at the inlet of the sprayingtube and through the rubber grommet.
10. Place the top cover assembly back into the unit.
11. Install tube #1 and tube #2 (ref. fig. 31) on the pumpassembly using the rubber elbows as shown in fig. 28.
12. Position pump assembly to the basepan as shown in fig.29 and fasten the pump bracket to the basepan using thethree screws provided.
13. Insert tube #2 of the pump assembly through the plasticgrommet of the sheet metal partition as shown in fig. 30.Then connect the end of tube #2 to the plastic elbowcoming out of the inlet of the spraying tube.
Figure 26
Figure 29
Figure 30
Figure 27
Figure 28
- 30 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
14. Connect the condensate pump to the ICRrelay of the terminal of the board as shownin fig. fig 32 & 34 whichever is applicableMake sure to fasten the pump wirethrough the wire clip on the back side ofthe control barrier as shown in fig. 33
15. Assembly the unit back following thereverse order of disassembly.
NOTE: All tube should be inserted into rubberelbows by at least 1/2 inch
Figure 31
Pump assembly
Tube #1
Tube #2
Rubber elbows(3)
Spraying Tube
Figure 32
BL BL
Figure 34
Figure 33
- 31 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
Architecture Grille Aluminum - SinglePackPart No: AYAGALA01
DescriptionOutdoor grilles are attached to the wall sleeve and exposed tothe exterior wall. The grilles are an industry standard size of42" x 16".
ReceivingUpon receipt of the product, inspect the shipping carton forsigns of visible damage. Report any damage or shortage tothe carrier and note it on the delivery receipt. The unit mustbe stored in its original shipping carton in a dry, secure placeprior to its installation and use.
InstallationThe installation and servicing of the equipment referred to inthis booklet should be performed by qualified, experiencedtechnicians.
WARNING
Hazardous Voltage!Disconnect all electric power, including remote disconnectsbefore servicing. Follow proper lockout/tagout procedures toensure the power can not be inadvertently energized. Failureto disconnect power before servicing could result in death orserious injury.
Important Note:The unit OFF switch does not disconnect all electrical powerto this unit.
Note:A baffle kit must not be used with a stamped aluminum grilleon any PTAC installation.
Stamped Aluminum Grille
1. Prepare the wall sleeve for installation of the grille byremoving the cardboard stiffener and rear enclosure panelfrom the sleeve. These items may be removed from insideof the building.
Note:The sleeve stiffener must be taken out before the rear sleeveenclosure panel can be removed from the sleeve.
2. Prepare the stamped aluminum grille for installation on thesleeve by inserting the six (6) plastic grommets into thesquare holes located near the outer edges of all four sidesof the grille. With the grille positioned so the flanges of allfour sides are in the up position, insert the grommets so thesquare end protrudes through the grille in the oppositedirection from the flanges.
3. Turn the grille so it can be removed through the rear sleeveopening.
4. Install the stamped aluminum grille by aligning the guidepins located in the lower right and left hand corners of thegrille with the corresponding holes in the rear of the wallsleeve.
5. Secure the grille by threading each of the screws into theplastic grommets.
6. Remove the wire handle (not shown in the picture) from thecenter of the grille prior to installing the chassis into thesleeve.
Note:Be sure to keep a firm grip on wire handle and grille toprevent it from dropping and/or causing possible injury orproperty damage.
Architectural Grille
1. Remove the cardboard sleeve stiffener and the rearenclosure of the sleeve as described in Step 1 of thestamped aluminum grille instructions.
2. Turn the grille so it can be removed through the rear sleeveopening.
3. Install the grille by aligning the four screws supplied to theircorresonding holes in the architectural grille.
Stamped Aluminum Grille
Architecture Grille
- 32 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
4. Secure the grille to the sleeve by tightening the four screwsto their corresponding holes in the grille.
5. Remove the wire handle after the installation is complete.
Note:The stamped aluminum grille includes 6 screws, washers,nuts, and plastic grommets. The architectural grille includes 4screws.
Condensate Drain kitPart No: AYDR101
DescriptionCondensate water will drain from the chassis into the sleeveduring normal heat pump operation. This can also occurduring times of high humidity when in cooling operation.Install either the outdoor or indoor drain kit components tocontrol the condensate water where normal drainage from thewall sleeve is not possible or undesirable. See Figure 35 forall components of the drain kit.
WARNING
Hazardous Voltage!Disconnect all electric power, including remote disconnectsbefore servicing. Follow proper lockout/ tagout procedures toensure the power can not be inadvertently energized. Failureto disconnect power before servicing could result in death orserious injury.
Important Note:The unit OFF switch does not disconnect all electrical powerto this unit.
ReceivingUpon receipt of the product, inspect the shipping carton forsigns of visible damage. Report any damage or shortage tothe carrier and note it on the delivery receipt. The productmust be stored in its original shipping carton in a dry, secureplace prior to its installation and use.
InstallationThe installation and servicing of the equipment referred to inthis booklet should be performed by qualified, experiencedtechnicians.
Drain InstallationNote:The optional drain kit serves only as a link between the unitand field-supplied condensate drain system. Installing the kit without connecting it to a drainage systemwill result in inadequate condensate removal, possibleleakage and corrosion.
Algaecide: Some algaecide products may cause damage tothe unit basepan and therefore should not be used. Contactyour sales representative when considering the use of acommercial algaecide. See Figure 35 for components of thedrain kit.
DRAIN FITTINGPLATE B
BLANK-OFFPLATE C
BLANK-OFFPLATE C
GASKETS A
1/2" DRAIN FITTING
MTG. SCREWS
MTG. SCREWS
BLANK-OFFPLATE D
GASKET E FORPLATE D
Figure 35 – Components of Drain Kits
- 33 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
Outdoor Drain Kit InstallationBefore installing the wall sleeve louvered condenser grille, itmust be determined if the optional outdoor wall sleeve drainkit is to be installed. The drain kit will allow the condensatefrom the outdoor and indoor coils to be routed to a suitablearea. The drain kit can be installed so the condensate can bedrained from the right or left hand side of the wall sleeve. SeeFigure 36. See local codes for proper condensate disposal.
To install the outdoor drain components proceed as follows:
1. Remove the rear enclosure panel and the sleeve stiffener.These items may be removed from the inside of thebuilding.
2. The drain fitting can be installed on the left or right handside of the sleeve. (Illustration will be for a right handinstallation.) Insert the drain fitting in the opening of gasketA and hole of plate B. Secure this assembly to the rear ofthe sleeve with two sheet metal screws into holes Gprovided in sleeve. See Figures 37 and 38.
3. Locate the other gasket A on the back of blank off plate Cand secure the assembly to the left rear of wall sleeve withsheet metal screws provided. See Figure 39 for finished lefthand side installation.
If the unit chassis is to be installed right away, install thecondenser grille to wall sleeve with hardware provided. Seecondenser grille installation instructions.
If the unit chassis will not be installed right away, replace therear enclosure panel in the wall sleeve. This will help protectthe inside of the building from weather damage.
If a subbase is used, be sure the right hand subbase cover isremoved before the chassis is installed in the sleeve. Slidethe chassis into the wall sleeve until the chassis flanges
contact the front edge of sleeve. Secure the chassis to thewall sleeve on each side with screws provided.
Re-install the cabinet front.
See the following pages for installation instructions of indoordrain kit.
1/2" DRAINFITTING
DRAIN FITTINGPLATE B
GASKETS A
MTG. SCREWS
BLANK-OFFPLATE C
Figure 36 – Outdoor Drain Kit Installation
G
PLATE "B"
DRAIN FITTING
BLANK-OFF PLATE
SHEET METAL SCREWS
Figure 37 Figure 38
Figure 39
See Detail A
Sleeve overflow portDo not close up this port
Gasket
MTG. Screws (2)
1/2" Outdoor Drain FittingDetail A
CoverPlate
Wall Sleeve Bottom
(4) Mounting Screws
Gasket (2)Blank-off Plate (2)
Figure 40
- 34 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
Indoor Drain Kit InstallationThe internal drain is installed on the bottom of the wall sleevewhen it is required to drain the condensate into a drainsystem inside of the building. The components of the wall sleeve drain kit are shown inDetail A. Use components C (2), D, E, mounting screws (6)and the Outdoor drain fitting.
1. The components D, E, and drain fitting of the kit aremounted on the bottom of the wall sleeve prior to theinstallation of the sleeve. It may be located in a feasiblearea on the bottom of the sleeve which is inside of theroom except when a subbase is used. When a subbase isinstalled, the drain may be a minimum of 3 1/2 " from thefront flange of the wall sleeve. The minimum clearanceshould provide adequate clearance for the subbase, seeFigures 40 and 41.
2. Cut out the template in the lower right hand corner of theseinstructions to locate the field drilled holes. (Two to mountthe plate and one for the Outdoor drain fitting). See DetailA on how the components have to be installed after theholes are drilled in the bottom of the wall sleeve. If thedrain fitting is not connected to an indoor drainage systemimmediately after the wall sleeve is installed, it must beplugged with a cork to prevent indoor water damage incase it rains.
An indoor tube or hose (furnished by others) must be installedon the drain fitting and interconnected to the drain systeminside of the building.
Install the two blank-off plates C and gaskets A on theoutdoor portion of the wall sleeve as shown in Figure 40.These components may be installed after the sleeve issecured in the wall opening just prior to the installation of thecondenser grille and chassis.
Leveling LegsPart No: AYLL101
DescriptionLeveling legs are designed to provide extra front support andleveling of the wall sleeve. Two leg assemblies are requiredper unit and are provided in each kit. Four screws are alsoprovided with each kit for attachment to the wallsleeve. See Figure 42.
The leveling legs must be installed before the chassis isinstalled, but after the wall sleeve is in place. Holes must be drilled in each side of the wall sleeve, belowthe duct package holes, for attachment to the wall sleeve.
Receiving• Compare kit identification number with sales order to ensure
that the correct kit has been received.• Inspect the leveling legs for shipping damage. File damage
claims with the delivering carrier immediately.
InstallationThe installation and servicing of this equipment should beperformed by qualified, experienced technicians.
Important Note:The unit OFF switch does not disconnect all electrical powerto this unit.
Checklist
The following is an abbreviated guide to leveling leginstallation. Refer to appropriate areas for more detailedinformation.
Figure 41
Hazardous Voltage!Disconnect all electric power, including remote disconnectsbefore servicing. Follow proper lockout/tagout proceduresto ensure the power can not be inadvertently energized.Failure to disconnect power before servicing could result indeath or serious injury.
WARNING
- 35 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
Leveling Leg Assembly
To install the leveling leg assembly, complete the following:
1. Drill two 1/8-inch holes in each side of the wall sleeve, asshown in Figure 43, using the leveling leg assembly as atemplate. Locations near the front of the sleeve providemore support.
2. Adjust the leveling legs to the approximate height neededand install them on either side of the wall sleeve, using thescrews provided. Bottom of wall sleeve can be anywherefrom three to five inches above the screw base. Caulkaround screws to prevent water leaks.
3. Level the sleeve horizontally from side-to-side. Provide aslight slope (one-quarter bubble in the sight glass) towardthe outside. Check the level again after the unit has beeninstalled. Adjust the legs as needed.
Installation on Wall Sleeve
1. Drill four 1/8-inch diameter holes in the wall sleeve, two oneach side, using the leveling legs as a template. Caulkaround screws to prevent water leaks.
2. Attach the legs to the wall sleeve, using the screwsprovided.
3. Adjust the leveling legs to level the wall sleeve from side toside and provide a slight pitch to the outside (one-quarterbubble in sight glass).
Adjuster Screw
Speed Grip Nut
Leveler Bracket
1/8" Diameter holes(four required per unit field-drilled)
1"
1/4"
1/2"
NOTES:1. Two leveling legs are supplied in each kit.2. One kit is required per unit.3. Fout mounting screws are provided in each kit.
Figure 43 - Leveling Leg Assembly
Figure 44 - Leveling Leg Installation on Wall Sleeve
- 36 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
Hard Wire KitPart No: AYAGALA01
DescriptionHard Wire Junction Box (Direct Wire Sub-Base) The hard wirejunction box kit is used to hard wire the unit when it is notdesirable to use the standard unit subbase or the unit powercord.The junction box provides a protected enclosure for electricalconnections as required by some electrical codes. The hard wire junction box is intended to be mounted on thefloor or the adjacent wall.
The junction box is furnished with approximately 2-1/2 feet of1/2-inch flexible steel conduit and a metal box for securing theconduit to the unit cabinet at the incoming power opening.
An optional 230/208V or 265V power switch assembly isavailable for use with the hard wire junction box or subbase.The switch provides a POWER ON/OFF function at the unitas required by some electrical codes. A replacement junction box cover plate is provided with eachswitch kit. For additional information, refer to the Power SwitchInstallation Instructions.
ReceivingUpon receipt of the product, inspect the shipping carton forsigns of visible damage. Report any damage or shortage tothe carrier and note it on the delivery receipt. Unit must bestored in its original shipping carton in a dry, secure placeprior to its installation and use.
InstallationThe installation and servicing of this equipment shouldperformed by qualified, experienced technicians.
Junction Box Kit Installation and WiringProcedureEIectrical connections at the unit must be made after the unitchassis is installed in the wall sleeve. The installer mustdetermine and supply the mounting components for attachingthe junction box to the wall or door.
WARNINGHazardous Voltage!Disconnect all electric power, including remote disconnectsbefore servicing. Follow proper lockout/tagout procedures toensure the power can not be inadvertently energized. Failureto disconnect power before servicing could result in death orserious injury.
Important Note:The unit OFF switch does not disconnect all electrical powerto this unit.
CAUTION
Use Copper Conductors Only!Unit terminals are not designed to accept other types ofconductors. Failure to use copper conductors may result inequipment damage. Important Note:All wiring must comply with applicablelocal and national codes. Types and location of disconnectswitches must comply with all applicable codes.
1. Remove the cover plate from the junction box2. Mount the junction box to the wall or floor within 28 inches (711
mm) of the lower right corner of the wall sleeve.3. If a disconnect switch is to be used, make electrical
connections to it and mount the switch in the junction box.Refer to the Power Switch Installation Instructions.
4. Remove control panel assembly by removing the two screwsholding control panel in place. Rotate the panel forward.
5. Disconnect the power cord leads from all electrical connectionsincluding the ground wire.
6. Remove the power cord clamp and the power cord from theunit.
7. For 208/230-volt units, remove and discard the white lead fromthe wire assembly. For 265-volt units, remove and discard thered lead from the wire assembly.
8. Remove the retaining ring from the threaded portion of thestraight conduit clamp. Insert the three wires into the metal boxthrough one of the two openings in the box. Replace the holecover grommet into the unused hole to prevent objects fromentering the box.
9. Replace the retaining ring back on the conduit clamp inside themetal box and tighten the ring securely.
10. Insert the three wires extending from the metal box into theincoming power opening on the unit so that approximately 20inches (508 mm) of the wires protrude through the opening.
11. Attach the metal box to the chassis with the two screwsprovided. See Figure 45.
12. Insert the wire tie into the 1/4-inch diameter hole located justabove the incoming power opening. Tie all wires togethersecurely with the wire tie. See Figure 46.
- 37 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
208/230 Volt Units1. Remove and discard the white lead from the wire
assembly.
2. Connect the black lead to the line 2 terminal on the controlboard.
3. Connect the red lead to the common (C) terminal on thecapacitor.
4. Connect the ground wire to the partition panel where theground wire on the power cord was located. Use the supplied green ground screw.
5. Connect the red lead in the wire assembly at the junctionbox to the red lead of the field power source.
6. Connect the black lead in the wire assembly at the junctionbox to the black lead of the field power source.
7. Connect the ground wire of the field power source to theground wire of the wire assembly at the junction box.
8. Install the junction box cover plate.
9. Reinstall the control panel assembly.
265 Volt Units1. Remove and discard the red lead from the wire assembly .
2. Connect the black lead to the center terminal of the fuseholder.
3. Connect the white lead to the common (C) terminal on thecapacitor.
4. Connect the ground wire to the partition panel where theground wire on the power cord was located.Use the supplied green ground screw.
5. Connect the white lead of the wire assembly at the junctionbox to the white lead of the field power source.
6. Connect the black lead of the wire assembly at the junctionbox to the black lead of the field power source.
7. Connect the ground wire of the field power supply to thebare ground wire of the wire assembly at the junction box.
8. Install the junction box cover plate.
9. Reinstall the control panel assembly.
Wall Sleeve
Cover plate
Control Panel
Base Pan
Bracket
Right Side of Chassis
3/16 InchDiamenter Hole
Back of Control Panel
Electrical Supply Wires
Ground Wiewith Eyelet
Terminal
Power Leads with Push on Connectors
Metal Box with Straight Clamp
Conduit
28 Inch es Max
Wire Tie
Figure 47 - Electrical Wiring Routing
Figure 46 - Metal Box Location
Figure 45 - Mounting Hard Wire Junction Box Kit
- 38 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
Fuse Holder KitPart No: AYFH1101
DescriptionThis optional fuse holder kit can be installed directly in thechassis or in the optional subbase. Fuse holder kits are available in 230/ 208 volt ratings. Theinstaller should supply time delay fuses at 15, 20, 25, or 30amps in accordance with the Maximum OvercurrentProtection as listed on the unit nameplate. Fuses may bepurchased from the parts department.
Note:The installation and servicing of this equipment must beperformed by qualified, experienced technicians only.
WARNING
Hazardous Voltage!Disconnect all electric power, including remote disconnectsbefore servicing. Follow proper lockout/ tagout procedures toensure the power can not be inadvertently energized. Failureto disconnect power before servicing could result in death orserious injury.
Important Note:The unit OFF switch does not disconnect all electrical powerto this unit.
CAUTION
Use Copper Conductors Only!Unit terminals are not designed to accept other types ofconductors. Failure to use copper conductors may result inequipment damage.
Important Note:All wiring must comply with applicable local and nationalcodes. Type and location of fused disconnect switch(es) mustcomply with all applicable codes. Failure to follow thesecodes could result in overheating and equipment failure.
ReceivingUpon receipt of the product, inspect the shipping carton forsigns of visible damage. Report any damage or shortage tothe carrier and note it on the delivery receipt. Unit must bestored in its original shipping carton in a dry, secure placeprior to its installation and use.
InstallationThe installation and servicing of the equipment referred to inthis booklet should be performed by qualified, experiencedtechnicians.
Fuse Holder Kit Installation(Without Subbase)1. Remove front by rotating bottom outward and then lifting up
and out from chassis.
Mode Switch
Thermostat
Remove two screwsto gain access insideControl Panel
Fuse HolderKnockoutsunder panel
Figure 48 - Control Panel
- 39 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
2. To gain access inside the control panel, after removing theknobs and escutcheon, remove the screws holding panel inposition. Tilt control panel forward, being careful not to pinch anywires. (Figure 48)
3. As viewed from the front, remove both knockouts on thecontrol panel.
4. Insert two fuse holders from the front. The fuse holdersshould be oriented so the quick-connect tabs are towardthe center of the unit. Attach fuse holders using the screwsand nuts provided. (Figure 48)
5. Remove both power cord leads, one lead from thecapacitor and one from the electronic board.
6. Install one power cord lead on the center terminal of onefuse holder. (Figure 49)
7. Install the remaining power cord lead on the center terminalof the second fuse holder. (Figure 49)
8. Connect BK-10 wire from the side terminal of one fuseholder to the Line terminal on the electronic board. (Figure 48)
9. Connect RD-10 wire from the side terminal of the otherfuse holder to the common (C) terminal on the capacitor.(Figure 49)
10. Tilt control panel back to original location, being carefulnot to pinch any wires. Align the control panel with thecover and screw panels into place with original screws.Replace escutcheon and control knobs.
Fuse Holder Kit Installation(With Subbase)See previous section for installation in the control panel.
1. Remove both knockouts at the fuse holder location. (Figure 50)
2. Install the fuse holders using screws provided. The sideconnector tab on the fuse holders should be towards theleft.
3. Connect a stripped BK-9 wire to the center of the quick-connect tab of the fuse holders. Wire nut the other end ofthis wire to the black field connection wire (TB1). (Figure 51)
4. Connect the other stripped BK-9 wire to the quick-connecttab on the side of the same fuse holder. Wire nut the other end to black subbase wire leading toreceptacle. (Figure 51)
5. Connect the stripped RD-9 wire to the center quick-connecttab of the second fuse holder. Wire nut the other end to thered field connection wire (TB3). (Figure 51)
6. Connect the other stripped RD-9 wire to the quick-connecttab on the side of the second fuse holder. Wire nut other end to red subbase wire which leads toreceptacle. (Figure 51)
7. Insert time delay fuses into the fuse holders. Size all fusesby the Maximum Overcurrent Protection shown on thenameplate. Also refer to the serial plate on the unit.
FUSEHOLDERS
Terminal Blocks Behind the Control Panel
Status Light
Fuse HolderKnockouts
LevelingLeg
ElectricalReceptacle
Fuseholder BK-9
Green
Black
Red
RD-9
Field ConnectionWiring
Fuseholder
Power SwitchKnockouts
Control Board
WH
GNBK
Transformer
Figure 49 - Fuse Holder Diagram Control Panel Installation
Figure 50 - Subbase (Left Side)
Figure 51 - Fuse Holder Diagram Subbase Installation
- 40 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
Remote Escutcheon KitPart No: AYRE110
DescriptionThis kit provides an attractive replacement escutcheon (seeFigure 52). The kit allows the removal of control knobs andgraphics, which are not required when a wall thermostat isused to control the unit.
ReceivingUpon receipt of the product, inspect the shipping carton forsigns of visible damage. Report any damage or shortage tothe carrier and note it on the delivery receipt. The unit mustbe stored in its original shipping carton in a dry, secure placeprior to its installation and use.
InstallationThe installation and servicing of the equipment referred to inthis booklet should be performed by qualified, experiencedtechnicians.
WARNING
Hazardous Voltage!Disconnect all electric power, including remote disconnectsbefore servicing. Follow proper lockout/ tagout procedures toensure the power can not be inadvertently energized. Failureto disconnect power before servicing could result in death orserious injury.
Important Note:The unit OFF switch does not disconnect all electrical powerto this unit.
1. Grasp the cabinet front as shown in Figure 53.
2. Pull the bottom of the cabinet front away from the chassisuntil the retaining clips disengage as in Figure 54.
3. Lift the cabinet front off the chassis.
4. Lifting the front edge of the escutcheon, slide the tabs atthe top of the escutcheon out of the retaining holes andremove the escutcheon. See Figure 55.
TEMP/TIME
MODE
HEATHEAT
E/SAVEE/SAVE
FANFAN
COOLCOOL
HIGHHIGH
LOWLOW TIMERTIMER
FAN TIMER
'F
ONOFFONOFF
F1 LOW
F2 HIGH
Figure 51—Standard Escutcheon
Figure 53
Figure 54
- 41 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
5. Replace the escutcheon with the one from this kit byinserting the tabs at the top of the escutcheon into theretaining holes and laying the escutcheon flat on thecontrol panel.
6. Replace the front by reversing steps 1 through 4.
7. Store the control knobs and escutcheon just removed fromthe unit for possible reinstallation if the wall thermostat isno longer desired.
SubbasePart No: AYSB1101 (230/208V 20A)
AYSB2101 (230/208V 30A)
DescriptionThe subbase may be installed on the wall sleeve before orafter installing the wall sleeve. The subbase is prewired.Electrical connections can be made on the left side after theaccess cover is removed. A grounding screw is provided.
ReceivingUpon receipt of the product, inspect the shipping carton forsigns of visible damage. Report any damage or shortage tothe carrier and note it on the delivery receipt. The unit mustbe stored in its original shipping carton in a dry, secure placeprior to its installation and use.
InstallationThe installation and servicing of the equipment referred to inthis booklet should be performed by qualified, experiencedtechnicians.
WARNING
Hazardous Voltage!Disconnect all electric power, including remote disconnectsbefore servicing. Follow proper lockout/ tagout procedures toensure the power can not be inadvertently energized. Failureto disconnect power before servicing could result in death orserious injury.
Important Note:The unit OFF switch does not disconnect all electrical powerto this unit.
CAUTION
Use Copper Conductors Only!Unit terminals are not designed to accept other types ofconductors. Failure to use copper conductors may result inequipment damage.
Note:When using a subbase, the wall sleeve must be installed aminimum of 3-1/4 inches (83 mm) above a finished floor and aminimum of 2-3/4 inches (70 mm) from a finished wall.
1. Remove parts B and C (Figure 57, next page) from thesubbase and join together using two metal screws provided.This assembly now becomes the right front cover (Part F) ofthe subbase. (Figure 56, next page)
2. Position subbase under the front of the wall sleeve.
3. Align the back edge of the flange on cover A (Figure 57, nextpage) to front of the wall sleeve flange. (Figure 58, nextpage)
4. Drill four 1/8 inch holes in wall sleeve to line up with holes insubbase. (Figure 57, Location D, next page) Mount subbaseto wall sleeve with four sheet metal screws provided with kit.(Figure 57, Location D, next page)
5. Remove the left front cover from the subbase. (Figure 57,Part A, next page)
6. Position skirting on each side of wall sleeve to prevent theentry of foreign materials. Trim skirting to desired length.Attach skirting with four sheet metal screws provided with kit.(Figure 57, Location E, next page)
7. Wire subbase for appropriate voltage (Figure 59, next page).
Escutcheon
Figure 55
- 42 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
Note: The proper subbase must be ordered to obtain the correctelectrical receptacle. (Figure 60)
8. After wiring is complete, mount covers A and F to thesubbase with provided screws. (Figure 57)
9. When installing optional accessories to the subbase, referto each installation instruction for that accessory.
Figure 55
Part/Location Identification
A
B
C
D
E
F
Left Front Cover
Right Front Cover
Front Cord Panel
Wall Sleeve Hole Location
Skirting Hole Location
Right Cover Assembly
Wall Sleeve
CoverWiring Access
SubbaseBox Assy
Low VoltageCompartment
2-13/16"(71 mm)
11-13/16"
(300 mm)
A B F
C
E
D
D
E
Wall Sleeve(Outdoor Side)
Wall SleeveInside Edge
Back of Flange "A"
13 3/4"
2 3/4"
2 5/8"
13-7/8" (352 mm)3-1/16"(78 mm)
Left End View
ConcentricKnockouts In Bottom
GroundScrew Location Receptacle Provided
Inside subbaseAccessory
Top View
ConcentricKnockouts In Rear
Field WiringLine Voltage
Field WiringLine Voltage
NEMA 6-20RReceptacle
230/208 VAC Field Schematic 265 VAC Field Schematic
NEMA 6-30RReceptacle
Voltage Subbase ReceptacleUnit Plug
NEMA 7-30RReceptacle
NEMA 7-20RReceptacle
Front View
20-5/16" (515.5 mm)
2" (50 mm) Max.Adjustment
4" (
101
mm
)2-
5/8"
(67
mm
)
2" (
50 m
m)
2 3/4"
16"16"
1-3/
8" (3
5 m
m)
Figure 57 - Part/Location Identification
Figure 58 - Dimensions
Figure 59 - Wiring Diagram
Figure 60 - NEMA Plug Configurations
- 43 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
5.1 OUTSIDE DIMENSIONS 1,066mm (42")
505mm (20")
406m
m (
16")
406m
m (
16")
5.2 PIPING SYSTEMFollowing is a brief description of the important components and their functions in the refrigeration system.Refer to Figure 61 to follow the refrigeration cycle and the flow of the refrigerant in the cooling cycle.
MOTOR
COMPRESSOR
OIL
(LIQUID REFRIGERANT)
CAPILLARY TUBE
OUTSIDE COOLINGAIR FOR REFRIGERANTPASS THROUGH
SUCTION LIMECOOL LOW PRESSURE VAPOR
COOLEDAIR
COMPLETE LIQUIDBOIL OFF POINT
LIQUIDPRESSUREDROP
ROOM AIR HEAT LOAD
VAPOR INLETHOTDISCHARGEDAIR
LIQUID OUTLET
HIGH PRESSURE VAPOR
LIQUID PEFRIGERANT
LOW PRESSURE VAPOR
ROOM AIR CONDITIONER
EVAPORATOR COILS CONDENSER COILS
CYCLE OF REFRIGERATION
Figure 60
5. troubleshooting guide
- 44 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
5.3 TROUBLESHOOTING GUIDEIn general, possible trouble is classified in two causes.The one is Starting Failure which is caused from an electrical defect, and the other is Ineffective Air Conditioningcaused by a defect in the refrigeration circuit and improper application.
Unit is running but cooling is ineffective
Ineffective Cooling
Check of outdoor coil(heat exchanger) & the fanoperation.
Check gas leakage.
Repair gas leak.
Replacement of unit if theunit is beyond repair.
Satisfactory operation withtemperature difference ofinlet & outlet air 44.6~50˚ F(7~10˚ C)
Check heat load increase.
Unexpected residue
Overloaded Circuit
Check of inside gaspressure.
Adjusting of refrigerantcharge
Malfunction of compressor
Replacement ofcompressor
Check of cold air circulation for smooth flow.
Dirty indoor coil(Heat exchanger)
Malfunction of fan
Clogged of air filter
Obstruction at air outlet
Correct above trouble
Check clogging in refrigeration circuit.
Repair clogging in refrigeration circuit.
- 45 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
Fails to Start
Check circuit breakerand fuse.
Gas leakage of feeler bulbof thermostat
Check control switch.
Only fan fails to start.
Improper wiring.
Defect of fan motorcapacitor.
Irregular motor resistance( ).Irregular motor insulation( ).
Replacement of fan motor
Regular but fails to start
Replacement of compressor(locking of rotor, metal)
Improper thermostat setting
Loose terminal connection.
Improper wiring
Irregular motor resistance ( )
Irregular motor insulation ( )
Replacement of compressor(Motor damaged)
Drop of power voltage.
Check capacitor.
Replacement.
Only compressor fails tostart.
Defect of compressorcapacitor.
Check power source.
Check control switchsetting.
- 46 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
COMPLAINT CAUSE REMEDY
Check voltage at outlet. Correct if none.
Check voltage to rotary switch. If none, checkpower supply cord. Replace cord if circuit is open.
Check switch continuity. Refer to wiring diagramfor terminal identification. Replace switch ifdefective.
Connect wire. Refer to wiring diagram for terminalidentification. Repair or replace loose terminal.
Test capacitor.Replace if not within ±10% of manufacturer'srating. Replace if shorted, open, or damaged.
Fan blade hitting shroud or cross flow fan hittingscroll. Realign assembly.
Units using slinger ring condenser fans musthave 1/4 to 5/16 inch clearance to the base. If it ishitting the base, shim up the bottom of the fanmotor with mounting screw(s).
Check fan motor bearings; if motor shaft will notrotate, replace the motor.
Check voltage. See limits on this page. If not withinlimits, call an electrician.
Test capacitor.Check bearings. Does the fan blade rotate freely?If not, replace fan motor.
Pay attention to any change from high speed tolow speed. If the speed does not change, replacethe motor.
Check grommets; if worn or missing, replace them.
If cracked, out of balance, or partially missing,replace it.
If cracked, out of balance, or partially missing,replace it.
Tighten it.
If knocking sounds continue when running orloose, replace the motor. If the motor hums ornoise appears to be internal while running,replace motor.
No power
Power supply cord
Rotary switch
Wire disconnected orconnection loose
Capacitor (Dischargecapacitor before testing.)
Will not rotate
Revolves on overload.
Grommets
Fan
Turbo fan
Loose set screw
Worn bearings
Fan motor will not run.
Fan motor runs intermittently
Fan motor noise.
- 47 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
NAME PLATE RATING MINIMUM MAXIMUM
208/230V 187V 253V
COMPLAINT CAUSE REMEDY
Check voltage. See the limits on the preceding.page. If not within limits, call an electrician.
Check the wire connections, if loose, repair orreplace the terminal. If wires are off, refer to wiringdiagram for identification, and replace. Check wirelocations. If not per wiring diagram, correct.
Check for continuity, refer to the wiring diagramfor terminal identification. Replace the switch ifcircuit is open.
Check the position of knob If not at the coldestsetting, advance the knob to this setting andrestart unit.Check continuity of the thermostat. Replacethermostat if circuit is open.
Check the capacitor.Replace if not within ±10% of manufacturersrating. Replace if shorted, open, or damaged.
Check the compressor for open circuit orground. If open or grounded, replace thecompressor.
Check the compressor overload, if externallymounted. Replace if open. (If the compressortemperature is high, remove the overload, cool it,and retest.)
Voltage
Wiring
Rotary
Thermostat
Capacitor (Dischargecapacitor beforeservicing.)
Compressor
Overload
Compressor will not run,but fan motor runs.
ROOM AIR CONDITIONER VOLTAGE LIMITS
- 48 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
COMPLAINT CAUSE REMEDY
Check the voltage. See the limits on the preced-ing page. If not within limits, call an electrician.
Check overload, if externally mounted.Replace if open. (If the compressor temperatureis high, remove the overload, cool, and retest.)
If not running, determine the cause. Replace ifrequired.
Remove the cabinet. inspect the interior surfaceof the condenser; if restricted, clean carefullywith a vacuum cleaner (do not damage fins) orbrush. Clean the interior base beforereassembling.
If condenser fins are closed over a large areaon the coil surface, head pressures will increase,causing the compressor to cycle. Straighten thefins or replace the coil.Test capacitor.Check the terminals. If loose, repair or replace.Check the system for restriction.If restricted, clean of replace.Close if open.Determine if the unit is properly sized for the area tobe cooled.Check the set screw or clamp. If loose or missing,correct. If the blower or fan is hitting air guide,rearrange the air handling parts.Carefully rearrange tubing not to contact,compressor, shroud, and barrier.
Voltage
Overload
Fan motor
Condenser air flowrestriction
Condenser fins(damaged)
CapacitorWiringRefrigerating systemAir filterExhaust damper doorUnit undersized
Cross flow fan
Copper tubing
Compressor cycleson overload.
Insufficient cooling orheating
Excessive noise.
- 49 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
6. Piping Diagrams
CAPILLARY TUBE
HEATEXCHANGE(EVAPORATOR)
HEATEXCHANGE(CONDENSER)
COMPRESSOR
ACCUMULATOR
CoolingHeatig
REVERSING VALVE
Th1
Th2
LOC. Description PCB Connector
Th1 Thermistor for indoor Air temperature CN-IDAT
Th2 Thermistor for evaporating temperature CN-IDPT
Th3 Thermistor for outdoor Air temperatureCN-ODT
Th4 Thermistor for condenser Air temperature
- 50 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
CN-ODT
CN-DISP1CN-DISP2
CN-IDAT
CN-IDPT
CN-AUX_S
CN-THERMO_S
CN-IDF
CN-4WAY
CN-ICR
CN-ODF
CN-LINK
P/NO:3850A20594H
BKBLRDORBRYL
BKRDBL
BK
BK
BKBLRD
OR(BR)YL
BK
OR(BR)YL
OLP
BKRDBL
F
HERM
R
COMP
BLRDORBRYL
GN/YL
FANCAPACITOR
GN/YL
GN/YL
Type.1
Type.1
In part "A", there are 3 types.
In part "B", there are 2 types.
Type.2
Type.3
INDOORFANMOTOR
INDOORFANMOTOR
OUTDOORFANMOTOR
OUTDOORFANMOTOR
OUTDOORFANMOTOR
Type.2
BKBLRDORBRYL
BKBLRDORBRYL
BKBLRD
OR(BR)YL
BKBLRD
OR(BR)YL
BK
OR(BR)YL
BKBLRD
OR(BR)YL
BL
OR(BR)YL
RDOR(BR)YL
BLRDORBRYL
BK
RDORBRYL
INDOORFANMOTOR
OUTDOORFANMOTOR
INDOOR COILTHERMISTOR
IND
OO
R C
OIL
TH
ER
MIS
TO
R
INDOOR AIRTHERMISTOR
IND
OO
R A
IRT
HE
RM
IST
OR
BK
WH
OR OR
OR
GN/YL
LIVEBK
NEUTRALWH
TB2TB1
BK1
BK2
BK3
BK4
RD
BL
RD
BL
"B"
"A"
7. schematic diagram
- 51 -Copyright ©2007 LG Electronics. Inc. All right reserved.Only for training and service purposes LGE Internal Use Only
F
E
B
753010
W50400
152302
135312330870
354210
349600
546810
559011549990
130411
554170
554030
148000
135515
135800
135500
567502
550140
A
237200
W0CZZB
W0CZZ
W6640
238310
268711B
249951
135511
147910
TEMP/TIME
MODE
HEATHEAT
E/SAVEE/SAVE
FANFAN
COOLCOOL HIGH
HIGH
LOWLOW
TIMERTIMER
FAN
TIMER
'F
ONOFFONOFF
ONOFFONOFF
268711A
249941A
249941B268711D
264110
D
346810
152302A
359011
352390
135500E
149400
337000
349600A
263230A
263230B
435300A
(InternalOLP typecompressors)
435300
C 552114 35211A 552113
352116
352115
8. Exploded View
Note) * Please ensure GCSC since the replacement parts may be changed depending upon the buyer's request.Please check the correct parts in View RPL(Replacement Part List) on GCSC.(GCSC Website http://biz.Lgservice.com,)
P/NO : MFL42137106 SEPTEMBER, 2008